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KESORAM RAYON

KESORAM RAYON. A CASE STUDY. KESORAM RAYON. MANUFACTURER OF - VISCOSE FILAMENT YARN - TRANSPARENT (CELLOPHANE PAPER) - SULPHURIC ACID - CARBON-DI-SULPHIDE - SODIUM SULPHATE EMPLOYEE STRENGTH = 2800 (approx.) TURNOVER (2001-2002) = Rs. 129 CRORES

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KESORAM RAYON

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  1. KESORAM RAYON A CASE STUDY

  2. KESORAM RAYON MANUFACTURER OF - VISCOSE FILAMENT YARN - TRANSPARENT (CELLOPHANE PAPER) - SULPHURIC ACID - CARBON-DI-SULPHIDE - SODIUM SULPHATE EMPLOYEE STRENGTH = 2800 (approx.) TURNOVER (2001-2002) = Rs. 129 CRORES ISO-9002 & ISO-14001 COMPANY LOCATED ON THE BANK OF RIVER BHAGIRATHI, ON 42 HECTARES OF LAND, 60 KM NORTH OF CALCUTTA

  3. OUR MAIN PRODUCTS Viscose Filament Rayon Yarn Transparent (Cellophane) Paper

  4. STEP-1 NORM FOR ENERGY USAGE - ELECTRICITY - STEAM - WATER Equip-ment No. Installed No. Run RPM Motor KW Actual KW Hours Run Sl. No. KWH/ Day

  5. STEP – 2 ELECTRICAL ENERGY • Improvement of Power Factor • Sizing of motors so as to prevent running on partial load. • Soft starters to reduce the energy wastage in high torque applications. • Improved alignment, bearing condition. • Vibration analysis, vibration monitoring. Contd….

  6. Step -2 (Electrical Energy contd…) • Proper sizing of pumps, to avoid thro- ttling of valves and consequent motor size reduction. • Use of lumen-efficient light fittings. • Deployment of energy efficient motors. • Application of frequency inverters for changing speed/flow. • On-Off level controllers to prevent continuous run of equipments.

  7. THERMAL ENERGY (STEAM/COAL) • Increase in combustion efficiency of boilers. • Heat recovery from continuous blow down water of boilers. • Preheating boiler feed water to 105oC/135oC • Better condensate recovery. • Application of proper design steam traps. • Rationalisation of Steam distribution. • Minimisation of HP steam usage by converting ejectors to LP steam. • Atomisation of Fuel and improvement of calci- nation dryer.

  8. REFRIGERATION • Segregation of usage as per temperature requirement. • Pipeline sizing to avoid pressure drop. • Installation of flow controllers to stop chilled water to equipments, once a predetermined level is reached. • Replacement of shell and tube type heat exchangers by plate heat exchangers. • Downsize refrigeration area to minimum required.

  9. CRITICAL EXAMINATION WHERE HOW MUCH WHEN HOW HOW ELSE WHY STEAM CONDENSATE AIR ELECTRICITY CHILLED WATER

  10. STEP - 3 • TOTAL SYSTEMS APPROACH • SELECTION OF EQUIPMENTS • EMPLOYEE INVOLVEMENT • INTER UNIT VISITS • OPTIMAL CAPACITY UTILISATION • UPGRADATION OF TECHNOLOGY • ENERGY AUDIT • REGULAR MONITORING OF IMPLEMENTED PROJECTS

  11. ENERGY AUDIT CONDUCTED BY 1. Tata Energy Research Institute 2. National Productivity Council 3. Balmer Lawrie & Co. Ltd 4. M.K. Raju Consultants (P) Ltd 5. Forbes-Marshall 6. Mazda Croll Reynolds Process Systems 7. Separation Engineers 8. Confederation of Indian Industry (CII) 9. M.K. Raju Consultants (P) Ltd. (for the current year 2002-2003)

  12. B.K. BIRLA GROUP OF COMPANIESENERGY POLICY We shall strive for continuous energy economy through – • Formulation of overall energy strategy and targets. • All round participation of all employees including casual and contractor labours with total commitment from top management. • Improved capacity utilisation. • Upgradation of process, technology and equipment. • Better plant layout. We shall maximise the Group’s synergy by way of sharing expertise, between the units, through inter-unit visits, zonal conference and audit by expert team. As a part of our energy conservation and environmental strategy, we are committed to reduce specific energy consumption by 1% every year by 2010. J.D. PALOD Chairman, Energy Conservation & Productivity Improvement Group B.K. Birla Group of Companies

  13. MAJOR ENERGY CONSERVATION PROJECTS IMPLEMENTED

  14. TOTAL ELECTRICITY CONSUMPTION (LAKH KWH)

  15. TOTAL ELECTRICITY PURCHASED (LAKH KWH)

  16. AVERAGE MONTHLY MAXIMUM DEMAND (KVA)

  17. COAL PURCHASED (MT)

  18. SPECIFIC ELECTRICITY CONSUMPTION (RAYON YARN)

  19. SPECIFIC ELECTRICITY CONSUMPTION (TP)

  20. SPECIFIC COAL CONSUMPTION (RAYON YARN)

  21. SPECIFIC COAL CONSUMPTION (TP)

  22. ENERGY CONSERVATION AWARDS NATIONAL ENERGY CONSERVATION AWARDS (a) For the year 1995 (1st Prize) (b) For the year 1996 (2nd Prize) (c) For the year 1997 (1st Prize) (d) For the year 1998 (1st Prize) (e) For the year 1999 (1st & Special Prize) (f) For the year 2000 (1st & Special Prize) (g) For the year 2001(Excellence Award) (h) For the year 2002(Excellence Award) Kesoram Rayon

  23. Sri J.D. Palod, President, receiving the National Energy Conservation ‘Excellence Award’ for the year 2002, from the Hon’ble Vice President of India.

  24. MAJOR PROJECTS IMPLEMENTED IN 2001-2002 Contd..

  25. Contd..

  26. ENERGY CONSERVATION MEASURES FOR 2002-2003

  27. ENERGY CONSERVATION MEASURES FOR 2003-2004

  28. ENERGY CONSERVATION TARGET

  29. A FEWCASE STUDIES

  30. STATIC INVERTOR IN PLACE OF ROTARYMGSET CONVERTORS(Exhibit – 1) EARLIER SYSTEM - MG-SETSPINNING POTMOTOR SUPPLY FREQUENCY = 123 TO 130 C/SROTORY CONVERTORS RATING = 2000 KVA PRESENT SYSTEM - INVERTOR FOR HF ELECTRICITY CONSUMPTION OF MGSET = 39000 KWH/DAYELECTRICITY CONSUMPTION WITH INVERTORS = 33000 KWH/DAYINVESTMENT = RS. 290 LAKHS

  31. COUNTER FLOW COOLING TOWER FOR POWER PLANT (Exhibit – 2) APPROACH TEMPERATURE 4 TO 50C APPROACH TEMPERATURE 0.50C TO 10C RESULTED IN INCREASE OF CONDENSOR VACUUM AND REDUCTION IN STEAM CONSUMPTION INVESTMENT = RS. 60 LAKHSANNUAL SAVING = RS. 55 LAKHS

  32. HEAT PIPE HEAT EXCHANGER FOR TP-DRYER (Exhibit – 3) EARLIER SYSTEM - FRESH AIR, HEATED THROUGH STEAM COILS CIRCULATE TO DRYING CHAMBERS, MOIST VAPOUR OF DRYER EXHAUSTED TO ATMOSPHERE AT 930C PRESENT SYSTEM - HEAT PIPE HEAT EXCHANGER DEPLOYED TO PREHEAT INLET AIR BY EXHAUST AIR OF DRYER HEAT RECOVERED = RS.2,40,000 KCAL/HOUR INVESTMENT = RS. 30 LAKHS ANNUAL SAVING = RS. 26 LAKHS

  33. VFD FOR ACID PLANT ROOTS BLOWER(Exhibit – 4) CAPACITY OF ROOTS BLOWER - 7000 NM3/HR AIR FLOW REQUIRED - 5000 NM3/HR FOR 50 TPD AIR FLOW CONTROL THROUGH DAMPER & BYPASS AIR FLOW CONTROL THROUGH VFD INVESTMENT = RS. 26 LAKHS ANNUAL SAVING = RS. 24 LAKHS

  34. WASTE HEAT RECOVERY OF ACID PLANT(Exhibit – 5) H2SO4 OF 950C REQUIRES TO BE COOLED TO 650C FOR PROPER ABSORPTION EARLIER SYSTEM CI CASCADE COOLERS, WHERE WATER IS SPRAYED FROM TOP & ACID COOLED. WATER DRAINED CONTINUOUSLY. PRESENT SYSTEM PLATE COOLER TO EXTRACT HEAT & UTILISE IN RAYON PLANT, THROUGH INTEGRATION OF SUB-SYSTEMS.

  35. SYSTEM INTEGRATION PRESENT SUB – SYSTEMS(Exhibit – 5) Steam Rayon Final Wash 400 gpm 450 gpm water LP Steam Heater Rayon Prewash To drain Water To ETP Condensate H2SO4 at 700C Water ACID COLLER To drain H2SO4 at 900C

  36. SYSTEM INTEGRATION RE-ENGINEERED SYSTEM(Exhibit – 5) RAYON PREWASH RAYON FINAL WASH ACID COOLER H2SO4 PLANT Water at room temp. H2SO4at90o C Water at 70o C INVESTMENT - RS. 45 LAKHS SAVINGS - RS. 4.7 LAKH KCAL/YEAR - 3200 CM WATER/DAY PAYBACK - 21 MONTHS

  37. SULPHUR RECOVERY PLANT(Exhibit – 6) EARLIER SYSTEM - TAIL GAS OF CS2 REACTORS - SCRUBBER FOR H2S, TRACES OF CS2 USING NaOH OF 14.5 TONS/MONTH. RESULTANT Na2S – TREATMENT IN ETP PRESENT SYSTEM - RECOVERY OF SULPHUR OF 300-400 KG PER DAY INVESTMENT - RS. 46.00 LACS ANNUAL SAVING - RS. 18.00 LACS

  38. REDUCTION IN AIR CONDITIONING VOLUME(Exhibit – 7) ANNUAL SAVING - RS. 2.10 LACS INVESTMENT - RS. 5.60 LACS FALSE ROOFING TO REDUCE HEIGHT FROM 22 FT TO 12 FT IN RIPENING ROOM & LAB. REDUCTION IN VOLUME - 14260 CFT REFRIGERATION LOAD REDUCED - 12 TR

  39. BEFORE THERMO COMPRESSOR(Exhibit – 8) STEAM HEADER 17.5 KG/CM2, 3700C TURBINE-1 0.65 MW TURBINE-2 0.65 MW TURBINE-3 1.5 MW PRDS LP HEADER (2.5 KG CM2) (14 KG/CM2) TO PROCESS TO PROCESS 2.2 KG/CM2) AFTER STEAM HEADER 17.5 KG/CM2, 3700C TURBINE-3 1.5 MW PRDS TO PROCESS (14 KG/CM2) (2.2 KG/CM2) TO PROCESS (2.5 KG/CM2) TO PROCESS

  40. THERMO COMPRESSOR(Exhibit – 8) STEAM SUPPLIED BY TG-1/TG-2 - 5.6 TPH(2.5 KG/CM2, 2600C) PRESENT POWER OUTPUT - 5600X24 - 6110 KWH/DAY 22 STEAM USED BY THERMO COMPRESSOR - 3.64 TPH OF 2.2 KG/CM2 1.96 TPH OF MOTIVE STEAM, AT 14.0 KG/CM2 PROPOSED POWER GENERATION FROM TG-3 - 3640X24 = 6240 KWH/DAY 14 REDUCTION IN MANPOWER COST, MAINTENANCE COST INVESTMENT = RS. 2.00 LACS ANNUAL SAVING = RS. 1.90 LACS

  41. L.P.STEAM HEATER(PREVIOUS)(Exhibit – 9) 400C WATER DEAERATOR BOILER 1000 C TURBINE STEAM 3700C 17.5 KG/CM2 750 KCAL/KG PROCESS HEAT GAINED FROM 40 TO 750 KCAL/KG

  42. L.P. STEAM HEATER(PRESENT)(Exhibit – 9) WATER 400C DEAERATOR LP HEATER BOILER 100 0 C 1250C TURBINE STEAM 3700C 17.5 KG/CM2 750 KCAL/KG TO PROCESS 646 KCAL/KG 2.0 KG CM2

  43. L.P. STEAM HEATER(Exhibit – 9) EXTRA STEAM PASSING THROUGH TURBINE GENERATES 2690 KWH/DAY INVESTMENT OF PROPOSAL - RS. 20.00 LACS ANNUAL BENEFIT - RS. 18.60 LACS

  44. USING PLANT SPENT WATER IN BOILERASH QUENCHING (Exhibit – 10) EARLIER SYSTEM • FRESH FILTER WATER WAS USED FOR BOILER ASH HANDLING SYSTEM @ 60 M3/HOUR PRSENT SYSTEM • T.P.PLANT WASTE WATER IS NOW USED FOR THE SAME INVESTMENT - RS. 2.4 LACS ANNUAL SAVING - RS. 7.2 LACS

  45. PROPER SIZING OF BUSBARS & TRANSFORMERS(Exhibit – 11) - REPLACEMENT OF TRANSFORMER - RELOCATION OF TRANSFORMER - REDUCTION OF JOINTS IN BUSBAR OF CARBON-DI-SULPHIDE REACTORS INVESTMENT - RS. 23.00 LACS ANNUAL SAVINGS - RS. 8.30 LACS

  46. ILLUMINATION EFFICIENCY(Exhibit – 12) • 36 WATT SLIM TUBE LIGHTS • HIGH EFFICIENCY – CU CHOKES/ ELECTRONIC CHOKES • LIGHTING TRANSFORMERS • 70W/ 120W SON LAMPS FUTURE PROPOSAL TO REPLACE 3700 TUBE LIGHTS - BY 28 WATT FITTING - BY CFL LAMPS TO REPLACE 220 SON LAMPS - BY 45W CFL LAMPS PROPOSED INVESTMENT - RS.28.00 LACS PROJECTED ANNUAL BENEFIT - RS. 10.5 LACS

  47. CARBON FIBRE SPINNING POT(Exhibit – 13)

  48. VAPOUR ABSORPTION HEAT PUMPS(Exhibit – 14)

  49. VAPOUR ABSORPTION HEAT PUMPS(Exhibit – 14) SAVINGS POWER - RS. 15.78 LACS STEAM - RS. 8.64 LACS MAINTENANCE - RS. 8.00 LACS TOTAL SAVINGS - RS.32.42 LACS INVESTMENT - RS. 100 LACS

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